Front-loading short CFD loops to integrate with engineering template

Abstract

In this competitive and fast evolving automotive market, it is crucial to progress forward in the product development process effectively and efficiently. One tool to achieve it is using knowledge-based engineering. The design and development of a component in a car is an intensive activity. Engineering template, a knowledge based engineering method is widely utilized to reuse the for-seen knowledge and reduce the lead time for the development. Though the engineering templates provide us with models that are competent, the model needs to be simulated and analysed before finalisation. In real world, it is not uncommon that the model generated from template, matures before the simulation results are delivered due to newly sprouted issues. This thesis is focused on integration of airducts into engineering template, more specifically airducts in the B-Pillar of a Volvo Car, with short CFD simulation loops in the early phase of product development with which quality models could be created. A standard product development procedure was followed to develop the solution for the thesis. Planning and pre-study were carried out to evaluate the current market situation and advancements in the field and also in the department. Essential stakeholders were identified and data were collected through interviews and focus groups. With the available information, parametrized template was developed for stable geometry creation for further usage during simulations. The model variants developed through the template were evaluated using the integration methods and results were graphed to compare with the reference result. This thesis has abridged the gap between CAE and concept design development using quick simulation in the early product development phase. The simulation in early phases is quite difficult, due to the fact, that the available stable CAD model data are scarce and inadequate. The design of the airduct changes rapidly before the CAE team could get back with the simulation result of the product. The developed solution diminish this drawback and carry out short and accurate simulations for the concepts to evaluate them before they are pushed to detail design. The conclusion of the thesis is, the developed solution to abridge the integration gap by salvaging around 30 minutes of the simulation time and the obtained results are almost accurate as the reference result, deviating between 2 to 10 pascals depending upon the intensity of mass-flow.